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Home >> Ford >> 1996 >> Aerostar Van Window >> Repair and Diagnosis >> External Pages >> Different car >> Section 140 (Engine - 4.9L 6-CYL - VIN [Y]) >> Removal & Installation >> Intake Manifold, Upper >> Installation

Intake Manifold, Upper: Installation

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 1996 Ford Pickup, 1996 Ford Econoline, 1996 Ford Club Wagon, 1996 Ford Cab & Chassis, and 1995 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position a new intake manifold upper gasket on the lower intake manifold, using the lower manifold dowels to position the intake manifold upper gasket. Position the upper intake manifold onto the lower intake manifold, using the dowels of the lower intake to locate manifold holes. Install the seven studs to attach the upper intake manifold to the lower intake manifold and hand-tighten.
  2. Tighten the seven studs attaching the upper intake manifold to the lower intake manifold to 16-24 Nm (12-18 lb-ft). Position the upper intake manifold support onto the boss of the upper intake manifold, located under the throttle body. Install the retaining screw and tighten to 30-43 Nm (22-32 lb-ft).
  3. Install the EGR valve to exhaust manifold tube between the EGR external pressure valve and the rear exhaust manifold. The tube is routed between lower intake runners No. 5 and No 6. Tighten both fittings to 34-47 Nm (25-35 lb-ft).
  4. Connect the PCV hose to the fitting, located on the valve cover under the upper intake manifold. Connect accelerator cable, transmission kickdown cable, and speed control actuator cable. Install accelerator control splash shield.
  5. Connect the air cleaner outlet tube to the throttle body. Install EGR transducer and bracket. Tighten screws to 17-24 Nm (12-18 lb-ft). Connect EGR transducer hoses.
  6. Connect the following vacuum connections: * vacuum line to the EGR external pressure valve * evaporate Emission (EVAP)system lines to throttle body * vacuum lines to the upper intake manifold vacuum outlet fitting and cap vacuum tree
  7. Connect the following electrical connectors at: * throttle position sensor * idle air control valve * EGR external pressure valve * evaporative emission canister purge valve
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